Weaving pile fabric



y 27, 1958 F. w. E. HOESELBARTH 2,836,201

WEAVING PILE FABRIC 6 Sheets-Sheet 1 Original Filed Feb. 4, 1954 fizrzf'iSEEZiraZ y 27, 1953 F. w. E. HOESELBARTH 2,836,201

WEAVING FILE FABRIC Original Filed Feb. 4, 1954 6 sheets-sheet 3 U 20 2/ f g 7 v [1 26 I f% fl ATTORNEYS May 27, 1958 Original Filed. Feb. 4. 1954 F. W. E. HOESELBARTH WEAVING PILE FABRIC 6 Sheets-Sheet 4 ATTORNEYS y 1958 F. w. E. HOESELBARTH 2,836,201

WEAVING FILE FABRIC Original Filed Feb. 4, 1954 6 Sheets-Sheet 5 Zfn 26 Z fl ATTORNEYS.

y 27, 1958 F. w. E. HOESELBARTH 2,836,201

WEAVING PILE FABRIC 6 Sheets-Sheet 6 Original Filed Feb. 4, 1954 ATTORNEYS.

Unite rates Patent() WEAVING PILE FABRIC Frank W. E. Hoeselbarth, Carlisle, Pa., assignor to C. H.

Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania Original application February 4, 1954, Serial No. 408,079. Divided. and this application March 14, 1955, Serial No. 493,853

13 Claims. (Cl. 139-39) The present invention relates to pile fabrics of the character of carpets and rugs.

The present application is a division of my copending application Serial No. 408,079, filed February 4, 1954, for Pile Fabric, which relates to the fabric itself.

A purpose of the invention is to increase the speed of production of pile fabrics such as carpets and rugs while obtaining a fabric of normal back construction.

A further purpose is to obtain a wider diversity of texturing in a pile fabric woven at a high production rate.

A further purpose is to provide a combination of pile areas in some of which the pile is raised over face wefts and in others of which the pile is raised over back wefts in accordance with pattern selection.

A further purpose is to selectively raise some of the pile warp ends over face wefts and some of the pile warp ends over back wefts and in certain pattern areas to raise all of the pile warp ends over back wefts.

A further purpose is to combine alternate raising of different pile warp ends over alternate face wefts in one pattern area with raising of the pile warp ends over back wefts in another pattern area, and permissibly with raising of some of the pile warp ends over back wefts in one pattern area and all of the pile warp ends over back wefts in another pattern area, and permissibly with raising of some of the pile warp ends over back wefts in one pattern area and all of the ends of pile Warp over back wefts in another pattern area.

A further purpose is to introduce the wires alternately from opposite sides, and to put one wire in with each of a pair of wefts introduced between reversals of the binder warp.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate one only of the numerous embodiments in which my invention may appear, selecting the form shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figures 1 to 8 inclusive are diagrammatic stepwise weave diagrams showing the production of a weave in accordance with the present invention.

Figure 9 is a diagrammatic warpwise completed weave diagram showing the fabric construction prior to the removal of the Wires.

In the prior art efforts have been made to accelerate weaving of pile fabrics by introducing Wires alternately from opposite sides. These weaves having in many cases been subject to the limitation that the hack of the fabric is not that of a normal woven carpet of the Brussels, Wilton, velvet or tapestry type.

The present invention is designed to increase and approximately double the output of weaving of a Brussels or Wilton fabric or permissibly of a velvet or tapestry carpet without increasing the loom speed.

The invention likewise is usefully applied to obtaining a wide variety of textured pattern effects. The weave can produce a combination of cut or uncut pile, or wholly cut or wholly uncut pile. The invention also makes possible the creation of certain pattern areas with alternate pile frames raised over alternate face wefts, while in other areas one pile frame or all frames as desired can be raised over back wefts.

The invention merely requires the introduction of a second wire motion on the opposite side of a carpet loom of the character of the Crompton and Knowles, or the Lansdowne, and the operation of the Jacquard at twice the normal speed with respect to the loom speed.

Considering first the weave as set forth in Figures 1 to 8, and comparing it with the wefts inserted on Figure 9, it will be seen that the relationship is as follows:

Step No Figure No.

l0 7 ll 8 12 4 13 1 Numbers of the steps have been inserted opposite the various wefts on Figure 9.

Considering first Figure 1, pile warp ends 20 manipulated by lingo heddles 21 are withdrawn over a suitable tensioning device 22 from a suitable source such as creel 23. Pile warp ends 24 manipulated by lingo heddles 25 are withdrawn through a suitable tensioning device 26 from a source such as creel 27. The invention is illustrated as applied to a loom using a jacquard mechanism, but it will be understood that in certain of its aspects it can be applied to velvet and tapestry carpet looms.

Binder warp 28 is manipulated by binder warp heddle 30 and withdrawn through tensioning device 31 from a siutable source such as beam 32. Binder warp 33 is manipulated by binder warp heddle 34 and withdrawn from the same source through the same tensioning device. While the particular weave illustrates the use of two binder warps, it will be understood that a single binder warp opposed to the stutter warp may be used if desired. Stuifer warp 35 manipulated by stuifer warp heddle 36 is withdrawn through tensioning device 37 from a suitable source such as beam 33.

In the first step as indicated in Figure 1, pile warp ends 20 are fully raised and binder warp ends 33 are raised half way, forming an upper shed 4t and all other ends are lowered, forming a lower shed 41. Wire 42 is inserted in the upper shed and a shot of weft 43 is inserted in the lower shed. The wire and weft are beaten up by lay 44. As shown in Figure 9 wire 42 is preferably a relatively low non-cutting wire, although it can be of a difierent height relative to the other wires and can be a cutting wire if desired.

In the second step as indicated in Figure 2, the relative position of the binder warp heddles remains unchanged, but all other warps are raised half way, forming a lower shed 41. A shot of weft 45 is inserted in the lower shed, and an unusual feature of the invention is that a wire 26 is inserted in what would normally be 7 the upper shed. While the wire 45 is without function at the position illustrated in Figure 2, it will be evident that in other pattern areas this wire will function as later explained in connection with steps 8 and 10. Wire 46 is preferably a high cutting wire, although it will be under stood that if desired it can'be of the same height or lower than wire 42 and can 'be a non cutting wire if desired.

In step3 as shown in Figure 3, the binder warp ends reverse and preferably. the pile warp ends are difiere ntly selected. Lingo 'heddles 25 are raised to fully raise ..pile warp ends 24, and 'the'lingo'heddles 21 are lowered to lower pile warp ends .20. Binder war-p'heddle'30 is raised 7 half way to raise binder warp '28'half way and binder warp heddle 34 is lowered to lower binder Warp 3'3. Stufier warp heddle 36 is lowered to lower stufier Warp 35." Wire 42 isinserted in the upper shed and a shot of weft 43 is inserted in the lower shed and the wire and weft are beaten up by the lay. It will be understood that wire 42willdesirably be'similar to previous wire 42, but

the successive wires 42 if desired can vary according to any desired pattern sequence. 7 a

In'step 4 as'shown in Figure 4, binder Warp 33 is lowered and all other warps are raised half way. A'

shot of weft45 is inserted in the lower shed 41 and an unusual feature is that a wire 46 is inserted in what would normally be the upper shed. The wire and weft are beaten up by the lay. Again the wire 46 .is without function in Figure 4 but is utilized at other pattern areas as later showni It will be seen that wefts 43 are in front of the stufier V warp or teams and are so called face or front wefts and wefts 45. are behindthe stuifer warp or warps and so are called back-wefts. 7

Step 5 is a duplicate of step 1 as'shown in Figure l and is not being repeated in the drawing. Step 6 is a duplicate of step 2 as'shown in Figure 2 and is not repeated.

' 'Step 7 is a duplicate of step 3 shown in Figure 3 and is not repeated. 7

It will be understood that steps of the character of steps l'to 7 will go on indefinitely as long as it is desired'to produce a pattern area of the type which these steps develop as at the left in Figure 9 In step 8 as shown in Figure 5, lingo heddles 21are.

. fully raised, raising pile warp ends 20, and liugo'heddles 25 are raised half way, raising pile warp ends 24 half ,way. Binder warp 28 and stufier warp 35 are raised halfway and binder warp 33 lowered. Wire 46 is inserted in the upper shed and a' shot of weft 45 is in:

sorted in the lower shed. An unusual feature of the weave is that in this step as dictatedby the pattern selection, pile or 7. a

V inserted in the lower shed and wire 42 is inserted in what would normally 'be the upper shed. Though wire 42 is without function in the position shown, at another pattern position it functions as illustrated in steps 1, 3, 5

Step 12 is identical withstep 4 of Figure'4 and step 1 3 is identical with step 1 of Figure 1.

It will thus be evident that the weave continues with any sequence of the various contrasting types of pile 7 shown which thepattern mayrequire for the 'difierentpat ll'l'l 31625. e

. Itwill of course be evident that the wires 42 within their group and the wires 46 within their group and the respective groups contrasting to one another maylbear the relation of high and low, low and high, equal in 7 height, straight noncutting, straight cutting, wavy and wavy (varying in height along their tops within the shed),

wavyand straight .or fla (having a high portion, at the end remote from the head beyond the shed), and any combination of these features may be used as desired.

' It will be evident that in the preferred embodiment of the invention the wires 42 and the wires 46 will be inserted from opposite sides of the fabric.

j It'will also be evident that the invention illustrates a fabric having a normal back and having areas in which two frames are raised in suitable uncut. alternating low pile, areas in which either frame is raised in desirably v high and desirably cut pile, and areas in which all frames warpends 20 are raised'in the pileopposite'back weft 45. At the same position, however, pile warp ends 24 are 'under the wire. The wire and weft are beaten up by the lay 44. If'desired, a pattern area cap be produced using steps like 7 and 8 in sequence, withreversals of the binder and stuffer warps.

In step 9 as shown in Figure 6, binder warp 33 .is

'raised half way and allother warps are lowered. A shot of weft 43 is takenin thelower shed and an unusual. feature is that though all pile warp ends are bound behind the weft, wire 42 is inserted in what would normally be theupper shed. At someother position in the pattern 7 this wire will function as insteps 1, 3, 5 or 7. The wire are raised in desirably high and desirablycut pile, and

that thejacquardrnechanism selects the particular charactor of pile which is to be created in a particular pattern area and the shape and extent of such pattern area." I In view of my invention and disclosure variations and p modifications to meet individual whim or particular need will doubtless become evident to others skilled'in the art, to obtain all orpart of the benefits of my invention without copying the process shown, and I, therefore, claim all such insofaras they fall within the reasonable spirit 7 V and scope of my claims. a

Having thus' described my invention what I claim as new and desireto secure by Letters Patent is: V

l. The process of weaving a pile fabric, using pile warp ends; binder warp ends, stutter warp ends and wefts, which comprises interweaving the pile warp ends, binder 'warp ends, stuifer warp ends and wefts, whileinserting two wefts between reversals of binder warp ends, inserting a wire with each weft, selectively as a pattern requires-raising some pile warpends'over a wire inserted with one weft'at one pair, selectively as the pattern.re-

quires carrying all pile warp ends in a particular pattern area beneath the wire inserted with the other weft of the pair, selectively as the pattern requires raisingother' pile warp ends over a wire inserted with the one weft of '7 theneXt pair, and selectivelyas the pattern requires carrying -all-pile warp ends in the particular pattern area beneath the wire inserted with the other weft of said next pair. 7 V i 2. The process'ofweaving apile f abrie, using pile warp ends, binder Warp ends, stuifer warp ends and wefts,

which comprises interweaving the pile warp ends, hinder warp ends, stuifer warp' ends and wefts, while inserting two wefts'between-reversals' ofbinderwarp ends, inserting awire with each weft and inserting the wires for a each pair ofwefts from opposite sides'of the fabric, se-

An unusual feature of steplO-is that at this-point-a'll. 'pile warpends in the particular pile area are raised over the wire introduced with the back weft. If desired a pattern area 'can'be produced using stepslike 9 and 10 in sequence,with reversals of the binder and stutter rp iln step 11, Figure .8, pile warp ends'20 and 24 and binder" warp,28 are raised half way, whilegbinderwarp 133 and stutter warp SS are lowered. A shot ofweft 43 is lectively j as a pattern requires raising some pile warp ends-over a wire inserted withthe first weft in one pair,

selectively as the pattern requires'earryingall pile warp ends in a particular pattern area beneat'n the wire inserted with the second weft of the pair, selectivelyas the pattern requires raising other pilclwarp ends over a wire inserted with the first weft of thesnextfpair and selectively as'the pattern requires carryingallpile warp ends in the particular patternarea'beneath the wire insorted with the second weft of .said next pair.

3. T he process of weaving a 'pile'fabric, using pilewarp ends, binder warp ends, stuifer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuifer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, selectively as a pattern requires raising some pile warpends over a wire inserted with one weft of one pair, selectively as the pattern requires carrying all pile warp ends in a particular pattern area beneath the wire inserted with one weft of the next pair and beneath such weft, and selectively as the pattern requires, raising all pile warp ends in the particular pattern area over a wire inserted with the other weft of said next pair.

4. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stuffer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuffer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft and from opposite sides of the fabric, selectively as a pattern requires raising some pile warp ends over a wire inserted with the weft of one pair, selectively as the pattern requires carrying all pile warp ends in a particular pattern area beneath the wire inserted with the first weft of the next pair and beneath such Weft, selectively as the pattern requires raising all pile warp ends in the particular pattern area over the wire inserted with the second weft of said next pair, and then carrying all pile warp ends in the particular pattern area beneath the wire inserted with the first weft of the next following pair.

5. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stufter warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuifer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, selectively as a pattern requires raising some pile warp ends over a wire inserted with one weft of one pair, selectively as the pattern requires raising other pile warp ends over a wire inserted with the other weft of the pair and selectively as the pattern requires raising all of the pile warp ends in a particular pattern area over a wire inserted with one of the wefts of the next pair.

6. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stutfer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuffer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, selectively as a pattern equires raising some pile warp ends over a wire inserted with one weft of one pair, selectively as the pattern requires raising other pile warp ends over a wire inserted with the one weft of the next pair, selectively as the pattern requires raising certain pile warp ends over a wire inserted with the other weft of said next pair and selectively as the pattern requires raising all pile warp ends in the particular pattern area over a wire inserted with a weft of a subsequent pair corresponding to the other weft.

7. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stuffer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, staffer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, raising certain pile warp ends over the wire inserted with the first such weft, and carrying said certain pile warp ends under the wire inserted with the second such weft, and carrying other pile warp ends under the wire inserted with the first such weft and raising said other pile warp ends over the wire inserted with the second such weft.

8. The process of claim 7, which comprises inserting one of said wires from one side and the other from the opposite side of the fabric.

9. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stuifer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stufier warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, selectively as a pattern requires raising certain pile warp ends over the wire inserted with the first such weft and carrying said certain pile warp ends under the wire inserted with the second such weft, and selectively as the pattern requires carrying other pile warp ends under the wire inserted with the first such weft and raising said other pile warp ends over the wire inserted with the second such weft.

10. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stufiz'er warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuffer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, selectively as a pattern requires raising some pile warp ends over the wire inserted with one weft of one pair and carrying said some pile warp ends under the wire inserted with the other weft of said one pair, and selectively as the pattern requires raising other pile warp ends over the wire inserted with a weft of the next pair corresponding in position to said one weft and carrying said other pile warp ends under the other weft of said next pair.

11. The process of claim 10, which comprises inserting alternate wires from opposite sides or" the fabric.

12. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stul'fer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuffer warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft and from opposite sides of the fabric, selectively as a pattern requires raising some pile warp ends over the wire inserted with the first weft of one pair and carrying said some pile warp ends under the wire inserted with the second weft of said one pair, and selectively as the pattern requires raising other pile warp ends over a wire inserted with the first weft of the next pair and carrying said other pile warp ends under the wire inserted with the second weft of said next pair.

13. The process of weaving a pile fabric, using pile warp ends, binder warp ends, stuifer warp ends and wefts, which comprises interweaving the pile warp ends, binder warp ends, stuifer Warp ends and wefts, while inserting two wefts between reversals of binder warp ends, inserting a wire with each weft, and selectively as a pattern requires raising some pile Warp ends over the wire inserted with the first weft of one pair and carrying said some pile warp ends under the wire inserted with the second weft of said one pair, selectively as the pattern requires raising other pile warp ends over the Wire inserted with the first weft of the next pair and carrying said other pile warp ends under the wire inserted with the second weft of said next pair, and selectively as the pattern requires raising pile warp ends different from those raised over the wire inserted With the first weft of said next pair, over a wire inserted with said second weft of said next pair.

References Cited in the file of this patent UNITED STATES PATENTS 8,281 Johnson Aug. 5, 1851 158,202 Cochrane Dec. 29, 1874 2,477,248 Harding July 26, 1949 2,685,894 Parlin Aug. 10, 1954 2,714,400 Harding Aug. 2, 1955 2,759,495 Masland Aug. 21, 1956 FOREIGN PATENTS 32,561 Germany Apr. 10, 1908 656,742 Great Britain Aug. 29, 1951 839,608 France Jan. 4, 1939 

